Pipeline Overview (Pipeline Operations)

© Hindustan Petroleum Corporation Ltd.
INTRO
TO
PIPELINE
PROJECTS
Projectअन्वेष
ण

Welcome to “Intro to Pipeline Projects”
Welcome to the Intro to Pipeline Projects. This course is designed for the Pipeline Project Engineers to help them
understand the overview of their function and SBU.
Please read the following pointers carefully:
You can use the Table of Contents or the Back button to navigate to any of the previously covered topics within this course.
There are Knowledge Check questions after every module. You can try them as many times as you like.
The course is followed by an assessment. You must score at least 70% in order to get credit.
In the event you do not score 70%, you will be required to go through the course again in order to retake the assessment.
The course would take approximately 40 minutes to complete. However, please feel free to pause as often as required.

Table of Contents
1
Overview
5minutes
PipelinesOverview
20minutes
Summary
5minutes
1 2
HPCLPipelines
10minutes

Key Terms
Term Definition
POL Petroleum Oil & Lubricants
JV Joint Venture
SCADA Supervisory Control & Data Acquisition Systems
OMC Oil Marketing Company
HSD High Speed Diesel
MS Motor Spirit
SKO Superior Kerosene Oil
LPG Liquefied Petroleum Gas
ATF Aviation Turbine Fuel
FO Furnace Oil
LDO Light Diesel Oil
PIG Pipeline Inspection Gauge

Course Objectives
After the completion of this course, you will be able to:
 Explain about Modes of Transportation of Petroleum Products
 Explain briefly about cross-country Pipelines
 Enumerate the advantages of Pipeline Mode of Transportation
 Learn about Pipeline Networks in India & HPCL
 List the Basic Pipelines System

Let’s Begin Overview
5 minutes

Overview
While going through the course you will cover the basics of pipeline projects, which includes:
 Different modes of transportation of petroleum products as well as the features that differentiate them
 Different cross-country pipelines, the advantages of the pipeline mode of transportation and its operational life; the components and the
basic essentials involved in the undertaking of a new pipeline construction.
As a Pipeline and Operations Officer, this course would lay the foundation
of understanding your job profile. It would equip you with the basic
knowledge of the domain and help you grasp the concepts underlying
various tasks and responsibilities.

Module 1
Pipelines Overview
20 minutes
1

Module Objectives
After the completion of this module, you will be able to:
 Explain the different modes of transportation of petroleum products
 Describe the functioning of cross-country pipelines
 Discuss advantages of pipeline mode of transportation
 Enumerate the operational life of pipelines

Modes of Transportation of Petroleum Products
It is an established fact that pipelines are preferred as a cost effective, energy efficient, safe and environment friendly
method of transportation for petroleum products and crude oil and are playing a leading role in meeting the demand for
petroleum products in India. Economic growth and expansion of infrastructure in India offers opportunities to better utilize
the existing pipeline network in addition to expanding it by constructing new pipelines.
Modes of transportation of petroleum products are:
Rail
Road
Sea
Pipeline
1
2
3
4

It is a safe and reliable mode of transport system.
It is an economical and dependable mode of transport system particularly to the sensitive and strategic areas.
It provides a long term infrastructural option.
The difficulties in handling large volume of products by rail from one loading point is reduced.
Minimum transit loss.
In pipeline containers remain static whereas the cargo is moved.
In case of other modes the container moves along with the products and returns empty carrying the dead load.
Pipeline reduces congestion in some heavy trafficked routes.
Pipelines As a Mode of Transportation
The cross-country pipelines also have advantage over the other modes of transportation for supply of petroleum products.
Let’s take a look at why it is more beneficial to have pipelines rather than using other modes of transport.
The advantages
of the pipelines
over the other
modes of
transport for
supply of
petroleum
products are:

The cross-country pipelines also have advantage over the other modes of transportation for supply of petroleum products.
Let’s take a look at why it is more beneficial to have pipelines rather than using other modes of transport.
The advantages
of the pipelines
over the other
modes of
transport for
supply of
petroleum
products are:
Pipelines As a Mode of Transportation (Contd.)
The pipeline is hardly affected by natural calamities like flood, earthquake etc.
Land cost is minimum because once pipeline is buried the land can be restored back for use.
The energy consumed per unit distance per unit weight of products moved by pipelines is comparatively much less than
railways.
The environmental impact on the pipeline is limited mainly to the period of laying the line and operation.
During operation there may be deterioration in the air quality owing to running of the pumps and emissions of hydrocarbon which
occur during storage and dispatch activities but of little effect on the environment.
Therefore the environmental impact on the pipelines is relatively insignificant as compared to other modes of transportation
system.

Petroleum Pipelines System: From The Wellhead To
The Consumers
Have you ever wondered what the journey of crude oil from wellheads through refineries up to you looks like? It’s truly
transformational. Literally, it is. And pipelines play a vital role in this journey. Let’s take a look at the two different types of
pipeline systems:
These pipelines are used to transmit various petrochemical products such as HSD, SKO, MS, LPG, etc. The pipe used for
these pipelines can vary from 2” to 42” in diameter.

Schematic
Typical schematic
illustrating a
pipeline system
from the wellhead
to the end
consumer

Cross-Country Pipelines
Pipelines usually span over hundreds of kilometres, covering areas across the country. Such pipelines are called cross-
country pipelines.
• A cross-country pipeline is generally laid across cross-country locations in
addition to Pipeline Operator’s own premises, mostly passing through
agricultural and waste lands and crossing various roads, railways, canals, rivers
and other utility lines en-route.
• The pipeline stations like pumping stations etc. will be developed in the lands
under the Pipeline Owner’s possession for respective purposes.
• Cross-country pipelines are generally laid underground maintaining a minimum
top cover of 1 meter duly following relevant statutory and technical
specifications.
• Sub sea / under water pipelines require specific approvals from concerned
authorities.
• Suitable Optical Fiber Cable (OFC) communication cables are also laid along
with pipeline for data and communication needs of pipeline operations.

Cross-Country Pipelines (Contd.)
Let’s take a look towards the different products that are transported in India through cross-country pipelines.
What Can Be Transported?
Crude Oil
Refined
Petroleum
Products
(HSD, SKO,
MS, ATF,
Naphtha,
Black Oil,
FO, LDO)
Petro-
chemical
Products Chemicals LPG Natural Gas
Any other
Gas
1 2 3 4 5 6 7

Operational Life of Pipelines
In addition to other parameters, HPCL is also concerned with the operational cycle of its pipelines.
The
Operational
Life of HPCL
Pipelines
Conventionally, pipelines are designed for continuous operation for a
period of 35 years.
These lines are however adequately protected against internal /
external corrosion and can be maintained in excellent condition.
There are pipelines which are under operation even beyond such
periods.
• Haldia – Barauni
• Gauhati - Barauni Pipeline

Check Your Knowledge
Select the correct answer.
Which of the following is NOT an advantage of Pipeline Mode of Transportation of POL Products?
 Safest Mode of Transportation
 Minimum Transit Loss
 Less Initial Investment
 Economical for long distances

Which of the following is NOT an advantage of Pipeline Mode of Transportation of POL Products?
 Safest Mode of Transportation
 Minimum Transit Loss
 Less Initial Investment
 Economical for long distances
Pipelines has high Initial Investment when compared to other modes of transportation.

Conventionally what is the Operational Life of a cross-country Pipeline ?
 15 Years
 25 Years
 35 Years
 55 Years

Conventionally what is the Operational Life of a cross-country Pipeline ?
 15 Years
 25 Years
 35 Years
 55 Years
Conventionally, pipelines are designed for 35 years, but, with proper maintenance, they
usually last longer.

Module Summary
You should now be able to:
 Explain the different modes of transportation of petroleum products
 Describe the functioning of cross-country pipelines
 Discuss advantages of pipeline mode of transportation
 Enumerate the operational life of pipelines

Module 2
HPCL Pipelines
15 minutes
2

Module Objectives
After the completion of this module, you will be able to:
 List various cross-country pipelines
 Describe the characteristics of HPCL pipelines in detail
 Explain the basic pipeline functionalities

Petroleum Pipelines: Industry & HPCL
India has been witnessing a steady increase in
its energy consumption, especially oil and gas,
for many years.
Sustained economic growth characterized by
increasing industrial activities has been the
main reason behind it.
The pipeline industry set its foot in India about
100 years back, when the first crude oil pipeline
was laid from Digboi oil fields to Digboi
Refinery.
However, its real development started only in
the 60’s.
During 1960-62, Oil India Limited laid the first trunk
crude oil pipeline from Naharkatiya and Moran oil fields
to the refineries at Guwahati and Barauni covering a
distance of 1156 km.
The first cross-country product pipeline was laid in 1964
by IOC to transport finished petroleum products from
Guwahati Refinery to Siliguri, crossing a number of
rivers and through diverse terrain in the states of Assam
and Bengal, covering a total distance of 435 km.
Subsequently, a number of other product and crude oil
pipelines were laid in the 70’s, 80’s and 90’s, including
sub-sea crude oil pipelines.
HPC commissioned its first petroleum product pipeline
i.e. Mumbai-Pune Pipeline in the year 1985 and BPC
commissioned its first petroleum product pipeline i.e.
Mumbai-Manmad Pipeline in the year 1998.

HPCL and Industry, subject to transportation of petroleum products.
Petroleum Pipelines: Industry & HPCL (Contd.)
The country has over 12000 km of major product pipelines (excluding LPG)
spread across length and breadth of the country.
Product is transported to the consumption centers either by pipeline or rail
and small quantity by road also.
It is also worth mentioning that the significant volumes of petroleum products
is still transported by rail.

HPCL’s Cross-Country Product Pipelines
Here are the name of pipeline with length in KMs and capacity in MMTPA.
Mumbai Pune Solapur Pipeline (MPSPL) 508 4.30
Visakh Vijayawada Secunderabad Pipeline (VVSPL) 572 5.38
Mundra Delhi Pipeline (MDPL) 1054 5.00
Ramanmandi Bahadurgarh Pipeline (RBPL) 243 4.71
Ramanmandi- Bathinda Pipeline (RBhPL) 30 1.13
Awa Salawas Pipeline (ASPL) 93 2.30
Providing Feedback to Ensure Reinforcement
Bahadurgarh Tikrikalan Pipeline (BTPL) 14 0.75
2
5
8
3
4
6
7
1

Existing Length and Capacity of Pipelines
The existing length and capacity of pipelines are shown below graphically.
The Length and
capacity of the
pipelines available
in India

HPCL Pipeline Infrastructure
For over a quarter
century now, HPCL
has been consistently
breaking new grounds
in production and
marketing. A glimpse
of the vast marketing
network already
developed is given
below in a table.
Pipeline Length
(Kms)
Present Capacity
(MMTPA)
MPSPL 508 4.30
VVSPL 572 5.38
MDPL 1054 5.00
RBPL 243 4.71
RBhPL 30 1.13
MHMSPL 356 1.94
Main Line 2763 22.46
ASPL 93 2.34
BTPL 14 0.75
RKPL 442 7.98
Branch Line 549 11.07
Others 58 3.6
HPCL Total 3370
PMHBL (JV Main line) 364 2.14
Total 3734
HPCL's infrastructure is at par with that of the best global corporations in the hydrocarbons sector.

HPCL Pipelines
3030
LEGEND
MDPL PIPELINE:
RECEIVING LOCATIONS:
PUMPING STATION:
(1054 KMS)
BAHADURGARH
PALANPUR
MUNDRA
SANTALPUR
AJMER
AWA
REWARI
JAIPUR
326 Kms
541 Kms
671 Kms
789 Kms
975 Kms
197 Kms
Length: 1054 km
Capacity : 5.0 MMTPA
Diameter : 18”/16”
Year Of comm : 2007
Projects and PipelinesMundra Delhi PipelineRewari Kanpur PipelineAwa Salawas PipelineMHMSPL LPG PipelineVisakh Vijaywada Secunderabad PipelineMumbai Pune Solapur PipelinePMHBL Mangalore Hassan Bangalore Pipeline (JV)
HPCL has a wide network of pipelines. Given below are the map locations of the pipelines and corresponding details.

Line Fill Quantities of Major Pipelines
Line Fill Volume = π x D2 x L (in KL)
4
D = Line Pipe Inner Dia in m
L = Length in m
Take a look to HPCL’s line fill quantities of its major pipelines.
S.No. Pipeline
Line Fill
Volume (KL)
1. Mumbai Pune Solapur Pipeline (MPSPL) 44182
2.
Visakh Vijayawada Secunderabad
Pipeline (VVSPL)
78100
3. Mundra Delhi Pipeline (MDPL) 160941
4. Ramanmandi Bhatinda Pipeline (RBhPL) 1570
5.
Ramanmandi Bahadurgarh Pipeline
(RBPL)
37402
6. Awa Salawas Pipeline (ASPL) 5020
7. Rewari Kanpur Pipeline (RKPL) 68,500

Any pipeline system will typically consist of following components. These components are detailed in further upcoming
slides.
Basic Pipeline System
Main Pump Station / Storage Terminal (Dispatch Terminal)
Main Pipeline
Intermediate Pump Stations
Intermediate Pigging Stations
1
2
3
4
Intermediate Tap-off Stations
Sectionalizing Valve Station
End Receipt Station / Terminal
5
6
7

Basic Pipeline System (Contd.)
• Storage Tanks
• Booster / Mainline Pumps
• Pressure Control & Metering
• PIG launcher
• Corrosion Inhibitor Injection
• Fire Fighting, Electrical & Instrumentation
Dispatch Terminal- Storage Facilities
1. Main pump station / storage terminal (dispatch terminal):
An originating pump station is the first installation in the cross-country pipeline having pumps for boosting the pressure of the liquid
hydrocarbon to be transported so that it reaches to next station in the cross-country pipeline. Facilities in Mainline Pump Stations includes:

Let’s take a look at various components of a dispatch terminal:
Piping Manifold Booster Pumps Booster PumpsMainline Pumps

Facilities in
Mainline
Pipelines are:
Line Pipe & Bends
Pipeline coating
Sectionalizing Valves & Appurtenance
Insulation Joint
Cathodic Protection
2. Main Pipeline:
Cross-country pipeline means all pipeline located beyond the boundary of any facility including pipelines after separator (exploratory well)
and its associated facilities which are required for transportation of liquid hydrocarbon from one point to another excluding piping within the
Refinery / Separation and or Processing plant up to plant isolation valves.

Pigging Facilities
Pumping Facilities
Sectionalizing valves &
appurtenances
3. Intermediate Pump Stations:
An intermediate pump station is any installation having facilities such as pumps etc. between originating pump station and intermediate
pigging station and / or terminal station / receipt station for boosting the pressure of the liquid required to reaches to next station.
Facilities in
Intermediate
Pump
Stations

An intermediate pigging
station is an installation
having facility for receiving
and launching of pigs for
pipeline pigging operations
and is located between
originating and delivery
stations.
Intermediate
Pigging
Stations:
Sectionalizing
valves &
appurtenances
Facilities in
Intermediate
Pigging
Station
Pigging
Facilities
4. Intermediate Pigging Stations:
The basic pipeline system works on a specific structure which happens to be a practice followed by HPCL is mentioned below:

Intermediate Tap-off Stations:
An intermediate delivery station / Tap off station / Points
on the pipeline installation is an installation having
facility to deliver product to any industry (ies) / storage
tanks through a tapping from the mainline. Delivery can
be through heart cut or full cut.
Facilities in
Intermediate
tap-off
stations
Pigging
facilities
Pressure
Control &
Metering
Storage
Tanks
Corrosion
monitoring
Fire Fighting,
Electrical &
Instrumentation
5. Intermediate Delivery Stations:
There are various essential elements constituted under the basic pipeline system. Lets take a look at these elements.

Sectionalizing Valve Station:
Valve (MOVs / HOVs) used in the
cross-country pipeline system for
isolation of a particular pipeline
section whenever required. This
valve is also referred as main Line
valve (MLV).
Sectionalizing
Valve Station
Facilities
Sectionalizing
Valves
Telecom
Repeater
Stations
Cathodic
Protection
Station.
6. Sectionalizing Value Station:
(Yet to mention)

Endreceiptstation/terminal
Facilities:
PIG receiver
Pressure Control & Metering
Storage Tanks
Corrosion monitoring System
Fire Fighting, Electrical & Instrumentation
End Receipt Station /
Terminal:
• Terminal / Receiving
station / Receipt terminal
is the last station on the
pipeline used for receipt
of liquid hydrocarbon
7. End Receipt Station / Terminal:
HPCL also has an end receipt station / terminal facilities under the basic pipeline system. These are shown as under:

What is the length of HPCL Pipelines Network?
 3300
 3970
 3370
 3100

What is the length of HPCL Pipelines Network?
 3300
 3970
 3370
 3100
HPCL has a total pipeline network of 3370 KM

Which among the following facilities will an Intermediate Pigging Station NOT have?
 Pig Receiving & Launching Facility
 Sectionalizing Valves
 Pumps
 Valves & Piping

Which among the following facilities will an Intermediate Pigging Station NOT have?
 Pig Receiving & Launching Facility
 Sectionalizing Valves
 Pumps
 Valves & Piping
An intermediate pigging station is an installation having facility for receiving and launching of pigs for
pipeline pigging operations and is located between originating and delivery stations. These stations
do not have Pump stations.

Module Summary
 List various cross-country pipelines
 Describe the characteristics of HPCL pipelines in detail
 Explain the basic pipeline functionalities

Summary
Summary
5minutes

Course Summary
 Explain about Modes of Transportation of Petroleum Products
 Explain briefly about cross-country Pipelines
 Enumerate the advantages of Pipeline Mode of Transportation
 Learn about Pipeline Networks in India & HPCL
 List the Basic Pipelines System

Pipeline Overview (Pipeline Operations)

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